DIY Network

Transmission Swap: Remanufactured Transmission A 1985 Chevy El Camino gets cured of the hesitation blues with a remanufactured transmission. From "Weekend Mechanic" episode WKM-406

Bruce Bonebrake compares the new and old transmissions.

In this project, Weekend Mechanic host Bruce Bonebrake discusses how to evaluate transmission problems by visual inspection, checking the transmission fluid for signs of debris and odor, and looking for clues in the way that the vehicle drives.

After determining that the transmission on our project car has serious mechanical issues, Bruce demonstrates the steps that are involved in removing and replacing a transmission. To save money and to ensure proper compatibility, he opts to install a remanufactured transmission that's the proper match for this vehicle.

The Problem

Our project car, a 1985 El Camino, has been leaving spots of transmission fluid in the driveway. There have also been times, during driving, where the transmission has been noticeably slipping between gears.

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The "new" remanufactured transmission

Project Overview

Bruce opens up the hood for a visual check and performs some preliminary tests--checking the transmission fluid, then checking the vacuum modulator hoses, transmission pan and filter, looking for possible leaks. Upon failing the tests for minor transmission repair, Bruce chooses a remanufactured transmission to replace the old one and goes through the steps in this ambitious installation. He removes the old transmission pan, removes some exhaust-system components and, using the proper equipment and safety precautions, lowers and removes the transmission. He then nspects related components and installs the new transmission. To complete the project, Bruce replaces the transmission pan with a new one, replaces the transmission fluid and takes the vehicle for a test-drive to check out the results.

DIY Difficulty Rating for the Project: This job requires removal and replacement of one of the most critical elements of the vehicle's drive-train, and involves some important safety considerations. We gave it a difficulty rating of 3 on a 5-point intermediate-level scale. Be sure to use the proper equipment, follow proper safety precautions and allow yourself the whole weekend to complete this job.

Important: Included here is a basic summary of the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit or replacement parts you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Used properly, the transmission jackstand safely supports the transmission as it is lowered from the vehicle.

Materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), some of the tools required for this project include

remanufactured transmission
transmission floor jack (transmission jack-stand)
impact wrench with an air compressor
drain pan for transmission fluid
pliers
cutters

Note: This particular project requires a specialized transmission floor-jack. Transmission jack-stands can often be rented and are specifically designed to aid in safe removal and installation of transmissions.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools. Also wear eye protection any time that you are working beneath a vehicle or around toxic or caustic fluids.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

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